US11786072B2 - Bun holding and thawing - Google Patents

Abstract

Systems and methods of bun handling include a cassette with opposed side walls. The cassette includes a front wall, an open rear face opposite the front wall, and a floor between the opposed side walls. A cover extends between the opposed side walls above the floor. The cover is movable relative to the opposed side walls and the floor. A slot is defined through the floor from the open rear face in a direction towards the front wall.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority of U.S. Provisional Patent Application No. 62/827,532, filed on Apr. 1, 2019, the content of which is hereby incorporated by reference in its entirety.

BACKGROUND

The present disclosure is related to the field of food preparation. More specifically, the present disclosure is related to systems and methods of handling baked goods for use in the assembly of sandwiches in a food preparation setting.

Many restaurant and food service settings, particularly quick service restaurants (QSR) use a combination of pre-prepared and on-demand prepared food components in order to assemble foods ordered by customers, for example, hamburgers or sandwiches within a customer's time expectation. While one approach to order assembly would be to sequentially prepare each food item constituent on demand in the order in which it is needed, customer food preparation time expectations in the QSR setting are frequently not met with such an approach.

Additionally, as the number of menu options and accommodation of customer special requests or customizations proliferate, there is a need for management of a greater number and variety of food items and constituents. Management of prepared food constituent inventory is more challenging as the number of food constituents increases. Also, as order assembly becomes more complicated, the assembly instructions are harder for food preparation workers to remember and correctly follow. This creates a greater learning curve for new or inexperienced workers or for the introduction of new menu items.

Bread, rolls, or other baked goods commonly form the structure on or within which the substance of a sandwich or other food item is held. Sandwiches, including hamburgers, club sandwiches, open-faced sandwiches, and wrapped sandwiches are commonly prepared foods in restaurants and kitchens. In the QSR, fast casual restaurant, or institutional kitchen setting, handling (and toasting, if necessary) of the baked good can take nearly half of the total time required to prepare the ordered sandwich. As a further challenge, if left exposed, baked goods can quickly become stale, prone to mold, or otherwise degrade in flavor.

The increase in different baked good options further presents a challenge as a greater number of specialty baked goods which are less frequently used must be kept available. As baked goods can quickly begin to degrade when exposed to an uncontrolled environment, solutions that can handle multiple types of baked goods are needed.

Most often baked goods are prepared off-site and delivered to the restaurant for subsequent use. Baked goods are frequently shipped to the restaurant in sealed air-tight bags, or “pillow packs.” These pillow packs may be filled with nitrogen or another gas that helps to preserve the baked goods while the air-tight seal is maintained. The baked goods may also be frozen to aid in the preservation of baked good quality during transport and delivery to the restaurant. Once at the restaurant, the pillow packs must be opened before the baked goods can be used and the baked goods must be thawed. As noted above, if left exposed, baked goods can quickly begin to degrade.

There is a trend in restaurants and food service for increased menu options and for accommodation of further customer custom requests. This adds to the complexity of food item orders and foodservice workers are less able to rely on memorization of food item recipes to assemble the order. Increased menu options and custom accommodations further contribute to slow the assembly of these food items.

Thus further solutions are needed for the handling and preparation of baked goods in a restaurant or foodservice setting, particularly in the holding and direction of baked goods into subsequent processing.

BRIEF DISCLOSURE

An example of a bun handling system includes a cassette with opposed side walls. The cassette includes a front wall, an open rear face opposite the front wall, and a floor between the opposed side walls. A cover extends between the opposed side walls above the floor. The cover is movable relative to the opposed side walls and the floor. A slot is defined through the floor from the open rear face in a direction towards the front wall.

In further examples of the bun handling system, the floor of the cassette further extends interior from the front wall, separating the slot from the front wall. The cassette further includes a plurality of lanes defined within the cassette between the opposed side walls. Each of the lanes of the plurality are separated from an adjacent lane of the plurality by an intermediate wall. The cassette may include a plurality of slots and each slot of the plurality of slots extends through the floor from the open rear face in a direction towards the front wall and each lane of the plurality of lanes includes a slot of the plurality of slots. The cover may further include a plurality of ridges that extend outwards from the cover. Each ridge of the plurality of ridges is vertically aligned with a slot of the plurality of slots. The cassette may be a first cassette and the bun handling system may include a second cassette. A plurality of ridges may extend from a cover of the second cassette and are dimensioned to nest within corresponding slots of the plurality of slots of the first cassette when the first cassette is stacked upon the second cassette.

Additional examples of the bun handling system include a bun holding cabinet that defines a compartment. The compartment of the bun holding cabinet may be configured to removably receive the cassette. The bun handling system may be configured to dispense a bun from a dispense point of the bun handling system to a toaster adjacent to the compartment. The cassette may be movable within the compartment to orient the cassette relative to the dispense point. The bun holding cabinet may include a first door into the compartment and configured to receive the cassette filled with a plurality of buns therethrough. The bun holding cabinet may include a second door into the compartment and configured for removal of the cassette after the buns are dispensed.

In further examples of the bun handling system, the bun holding cabinet may include a conveyor arranged within the compartment. The conveyor may be receivable within the slot to extend through the slot to engage a bun within the cassette. The cassette may include a plurality of lanes separated from an adjacent lane of the plurality of lanes by an intermediate wall, and a plurality of slots including the slot, each slot of the plurality of slots extends through the floor from the open rear face in a direction towards the front wall, each lane of the plurality of lanes having a slot of the plurality of slots. The plurality of conveyors may be arranged within the compartment, each of the conveyors of the plurality of conveyors configured to be receivable within a slot of the plurality of slots. The plurality of conveyors may extend through the plurality of slots to engage buns in each lane of the cassette. The plurality of conveyors may be received within the plurality of slots, the plurality of conveyors extend out of the open rear face of the cassette and are operable to move buns from each lane of the cassette out of the open rear face of the cassette. The compartment may include at least one shelf that extends interior the compartment. When the cassette rests on the at least one shelf, the plurality of conveyors are positioned within the plurality of slots.

Additional examples of the bun handling system include a thawing rack with a plurality of shelves. Each shelf of the thawing rack is configured to receive the cassette. The thawing rack further includes a plurality of back walls each oriented relative to one of the shelves of the plurality of shelves. When a cassette is received on a shelf of the plurality of shelves, the shelf covers the slot and the back wall covers the open rear face. The shelves of the plurality of shelves may be spaced apart at a distance to accommodate at least two cassettes in a vertical stack.

An example of a bun handling system includes a plurality of cassettes. Each cassette of the plurality includes opposed sidewalls, a front wall, an open rear face opposite the front wall, and a floor between the opposed side walls. A plurality of lanes are defined within the cassette between the opposed side walls, each of the lanes separated from an adjacent lane of the plurality of lanes by an intermediate wall, and a plurality of slots extend through the floor from the open rear face of the cassette in a direction towards the front wall and each lane of the plurality of lanes includes a slot of the plurality of slots. A cover extends between the opposed side walls above the floor. The cover is movable relative to the opposed side walls and the floor. The cover includes a plurality of ridges extending outward from the cover and each ridge of the plurality of ridges is vertically aligned with a slot of the plurality of slots. A bun holding cabinet includes a compartment. The compartment of the bun holding cabinet is configured to removably receive each cassette of the plurality of cassettes. The bun holding cabinet includes a plurality of conveyors arranged within the compartment. Each of the conveyors of the plurality of conveyors is configured to be receivable within a slot of the plurality of slots. The plurality of conveyors extend through the plurality of slots to engage buns in each lane of the cassette. The plurality of conveyors extend out of the open rear face of the cassette and are operable to move buns from each lane of the cassette out of the open rear face of the cassette.

The bun handling system may include a thawing rack with a plurality of shelves, each shelf of the thawing rack configured to receive at least one cassette of the plurality of cassettes, the thawing rack further comprising a plurality of back walls each oriented relative to one of the shelves of the plurality of shelves. When the cassette is received on a shelf of the plurality of shelves, the shelf covers the slot and the back wall covers the open rear face.

A method of dispensing buns from a bun handling system includes receiving a plurality of buns in each lane of each of the plurality of cassettes. The plurality of cassettes are received within the compartment of the bun holding cabinet. The plurality of conveyors are positioned through the slots of a cassette of the plurality of cassettes to engage the plurality of buns within the cassette with the conveyors. At least one conveyor of the plurality of conveyors is advanced to move a bun out of the cassette to a dispense point of the bun holding cabinet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG.1 is a system diagram of an exemplary embodiment of a holding cabinet of a baked goods handling system.

FIG.2 is a perspective view of the baked goods handling system.

FIG.3A is a schematic depiction of a cassette and a conveyor.

FIG.3B depicts an example of a portion of a compartment of a holding cabinet with a cassette and a conveyor.

FIG.3C is a side view taken alongline3C-3C ofFIG.3B.

FIG.4A depicts a thawing rack without bun cassettes.

FIG.4B depicts the thawing rack ofFIG.4A exemplarily loaded with bun cassettes.

FIGS.5A-5C depict an example of a bun cassette.

DETAILED DISCLOSURE

As provided herein exemplary embodiments of devices and systems for handling and dispensing baked goods in a restaurant or food service setting. The systems and devices as disclosed herein can be exemplarily used to handle a wide variety of baked goods, including but not limited to buns, rolls, English muffins, croissants, bagels, muffins, flatbread, pitas, cakes, pastries, and so forth.

The present disclosure relates to the handling and processing of baked goods in a food preparation and/or restaurant setting. Applicant's currently pending U.S. Patent Application Publication No. 2019/0167040 entitled “Baked Good Handling System”, No. 2019/0208964 entitled “Bun Holding Cabinet”, and No. 2019/0208793 entitled “Bun Separation” all relate to the handling and processing of baked goods and are each hereby incorporated by reference in their entireties.

FIG.1 is a system diagram of an exemplary embodiment of a holdingcabinet12. The holdingcabinet12 includes adispenser14 that operates with one ormore dispenser actuators46, for example, gates, conveyors, and/or pushers, that move buns held within the holdingcabinet12 to a next step in the baked good handling system. That next step in the baked good handling system may be a toaster, a sauce dispenser, packaging, or another system as will be recognized by a person of ordinary skill in the art.

Aprocessor24 is communicatively connected to anIOT communication system22 which facilitates communication with a kitchen management system (KMS)20 which operates to receive customer orders, track the progression and delivery of customer orders, and coordinate the preparation of customer orders between a plurality of devices within a kitchen system. TheKMS20 may also track inventory and use of food items by the various systems within the kitchen. Theprocessor24 receives the instructions regarding a bun required to assemble an ordered sandwich. Theprocessor24 coordinates the operations and functions of thebun holding cabinet12 and thedispenser14 by providing control signals and instructions to various components of the system and collecting data and information from the operation of the system to report back to the KMS through theIOT communication system22. As used herein, the term processor means any of a variety of known controllers, microcontrollers, integrated circuits, and/or printed circuit boards operable electronic to read and execute computer readable code to produce instructions and control commands as described in further detail herein. Theprocessor24 is further communicatively connected to a computer readable medium (CRM)26, which is non-transient and stores computer readable code that is executable by the processor, and upon execution causes the processor to carry out the functions and operations as described in further detail herein.

Theprocessor24 is further connected to at least oneinput device28 associated with thebun holding cabinet12. Theinput device28 may exemplarily include, but is not limited to, a keyboard and/or a touchscreen interface. Theinput device28 is operable by a foodservice worker to perform a manual entry of a control or operation of thebun holding cabinet12. These instructions received by theprocessor24 from theinput device28 may be instead of or in addition to those received from theKMS20. In an embodiment, the foodservice worker may use theinput device28 to request a dispense of a particular bun for a special order sandwich to be prepared manually, or as a replacement for a bun damaged elsewhere during assembly of the sandwich. The foodservice worker may have the option to input or control any of the parameters and functions as described herein.

Thebun holding cabinet12 includes acompartment30 that defines an enclosed area within which a plurality ofcassettes32 of buns are held. Thecassettes32 will be described in further detail herein. Thecassettes32 may be loaded into thecompartment30 through adoor34 in thebun holding cabinet12. In embodiments, thedoor32 may open with a vertical hinge, while in other embodiments, thedoor32 may open with a horizontal hinge. It will be recognized that in still further embodiments, thebun holding cabinet12 may include a plurality of doors rather than a single door into thecompartment30. In one such embodiment, thecabinet12 may be configured to hold a plurality ofcassettes32 in a vertically stacked arrangement as depicted inFIG.1, and adoor34 is provided for eachcassette32 row in the vertical stack. In another embodiment, at least one door may be used to loadcassettes32 into the compartment, while at least one other door may be used to removecassettes32 from the compartment.

Theprocessor24 is communicatively connected to one or moreenvironmental control devices36. Theenvironmental control devices36 are operatively connected to thecompartment30 and may include atemperature control device38 which may include a heating element and/or a refrigeration system depending upon the conditions for optimal holding of the bun within thecompartment30. Theenvironmental control devices36 may further includehumidity control40, which may include a humidifier and/or a dehumidifier to add or remove moisture from thecompartment30. Theenvironmental control devices36 may further includegas concentration control42 which may include supplies of gasses, for example, but not limited to, nitrogen or carbon dioxide that can be added to thecompartment30 to preserve bun freshness and inhibit spoilage before the buns are dispensed. While not depicted inFIG.2, each of theseenvironmental control devices36 include associated sensors related to the environmental conditions to be controlled, these may include temperature sensors, humidity sensors, and gas composition sensors located in or directed to thecompartment30.

Theprocessor24 is communicatively connected to at least onecabinet actuator44. The cabinet actuator44 exemplarily operates to move thecassettes32 and/orbuns50 within thecompartment30 to control the type and order in whichbuns50 are removed from thecompartment30. In examples provided herein, thecabinet actuators44 may operate to move thecassettes32 within thecompartment30. In examples provided herein, thecabinet actuators44 may operate to move individual buns from within acassette32 to thedispenser14. Further examples may operate to move both thecassettes32 and the individual buns withincassettes32. As described herein, thecabinet actuators44 may include mechanical elevators, lifts, pushers, or conveyors to position thecassettes32 within thecompartment30 and/or to move individual buns from thecassettes32.

FIG.2 depicts another example of a bakedgoods handling system10 within the scope of the present disclosure. The holdingcabinet12 receivescassettes32 of the baked goods (e.g. buns50) through adoor34A into thecompartment30. Thecompartment30 provides a controlled environment in which the buns are held prior to dispense. Thedoor34A exemplarily is horizontally hinged and located at the bottom of the holdingcabinet12. Thecassettes32 are loaded into the bottom of thecompartment30 and are moved into a position for dispense by thecabinet actuators44 located therein. This limits the portion of thecompartment30 that is exposed or opened each time that anew cassette32 is loaded into thecompartment30. Thecompartment30 may hold a plurality ofcassettes32 therein. The cabinet actuators44 move thecassettes32 to a dispensing position. The cabinet actuators44 may be a mechanical elevator, lift, or conveyor that positions thetrays32 within thecompartment30 of the holdingcabinet12. Thebuns50 are dispensed from thecassette32 in the dispensing position within thecompartment30, for example a position that is in alignment with thedispenser14 and/or adoor54 that leads to thedispenser14. The holdingcabinet12 dispenses selected baked goods from thesecassettes32. Thedispenser14 exemplarily includes aramp56 that directs abun50 by gravity feed to position abun50 relative to thetoaster16.

In examples, thecassettes32 are held within thecompartment30. Thecassettes32 are movable and removable within thecompartment30 to loadbuns50 into the compartment and to removeempty cassettes32 from thecompartment30 for refilling withbuns50. In such examples, once loaded into thecompartment30, thecassettes32 remain in a stationary position within thecompartment30.Cabinet actuators44, as described herein, engagebuns50 within thecassettes32 to selectively movebuns50 from thecassettes32 to thedispenser14. In such examples, the holdingcabinet12 may includemultiple doors54 or may include adoor54 of a sufficient size to enable dispense ofbuns50 from multiple locations ofcassettes32 within the compartment. In still further examples, shuttles, arms, or other actuators as described US Patent Application Publication Nos. 2019/0167040, 2019/0208964, and 2019/0208793 may move a bun removed from thecassette32 by the cabinet actuator44 to thedispenser14 or thetoaster16.

As depicted inFIG.2, thecassettes32 are exemplarily movable in a vertical direction along rails43. This may also provide for inventory management as somecassettes32 may be dedicated to specialty or lower volume baked goods whileother cassettes32 may be dedicated to high volume baked goods. The high volume baked goods can thus be used and replenished more frequently while the holding cabinet maintains the quality of the specialty/lower volume baked goods awaiting use in an order. Thecassettes32 may fit one across a width of thecompartment30, while in other examples, two ormore cassettes32 may fit across the width of thecompartment30 and individual stacks ofcassettes32 may be movable within thecompartment30. WhileFIG.2 depicts acassette32 that matches the width of thecompartment30, other examples may provide two or more vertical columns or stacks of cassettes that are exemplarily half-width or third-width, whereby each column ofcassettes32 holdsbuns50 of a different type. Correspondingdoors34A may only extend across thecompartment30 for a dimension sized to fit the cassette to be received therein. This, for example, may provide storage, management, and dispensing of two or more different types of buns from asingle holding cabinet12.

Thecassettes32 may be configured to receive a cabinet actuator, exemplarily a conveyor or a pusher that operates to engage abun50 or plurality ofbuns50 within acassette32 at the dispense position to advance abun50 out of thecompartment30. While not depicted inFIG.2, the holdingcabinet12 includessuch cabinet actuators44. These cabinet actuators44 are exemplarily depicted and described later herein with respect toFIGS.3A-3C.

In an exemplary and non-limiting description of operation of the holdingcabinet12,cassettes32 filled withbuns50 are loaded into the bottom of the holdingcabinet12 throughdoor34A. The holdingcabinet12 creates and maintains a controlled environment within thecompartment30 of the holdingcabinet12. As more buns are needed/used, the holdingcabinet12 movescassettes32 upwards from a position at thedoor34A to a position adjacent the dispensing position, for example relative to thegate54 and/or thedispenser14. This cycles a cassette filled with buns to the dispensing position to replace an empty cassette or to replace a cassette filled with buns determined to be held beyond a holding time limit. Exit of thebuns50 from the holdingcabinet12 may be controlled by thegate54 or with acabinet actuator44 that engages the buns. As described above, this may be pusher or a conveyor. Examples of aconveyor cabinet actuator44 are described in further detail with respect toFIGS.3A-3C. Once thebuns50 from acassette32 have been dispensed, the holdingcabinet12 moves the empty cassette further up along therails43 within thecompartment30 of the holdingcabinet12 for storage and/or removal from adoor34B, which may be located at the top of the holdingcabinet12 at a position above the dispense position. As previously described, acassette32 filled withbuns50 can then be loaded into the dispensing position within the holdingcabinet12. Anew cassette32 filled withbuns50 can be loaded into thecompartment30 through thedoor34A. It will also be recognized that this order of loading and unloading may also be reversed. A person of ordinary skill in the art will recognize variations from this disclosed embodiment that are within the scope of the present disclosure.

FIGS.3A-3C depict related examples of the interaction between acassette32 and a cabinet actuator in the exemplary form of aconveyor60, for example as may occur within acompartment30 of a holdingcabinet12 as described above. As depicted inFIG.3A, theconveyor60 and thecassette32 are movable with relative to each other, within thecompartment30. It will be recognized that while thecassette32 is depicted inFIG.3A without acover82 or afront wall90 as described in further detail herein, thatcassettes32 may also include those features, while inFIG.3A, removal of those features promotes visibility of the inside of thecassette32. Furthermore, while thecassette32 inFIG.3A is configured to receive a single row of buns therein, it will be recognized through other examples provided herein that cassettes may be configured to receive other number of rows of buns.

Thecassette32, filled withbuns50 moved to the dispensing position within thecompartment30 and theconveyor60 is movable within aslot62 through afloor64 of thecassette32. In one example, one set of conveyors may be arranged relative to the dispensing position and theconveyors60 moved through the slot to engagebuns50 in thecassette32 at the dispensing position. Thebun50 rests on thefloor64 of thecassette32, straddling theslot62. Extending through theslot62, theconveyor60 engages thebun50, lifting it from thefloor64 of thecassette32. In an example, thebun50 may remain in contact with thefloor64, while in other examples, lifting thebun50 with theconveyor60 off of thefloor64 helps to reduce friction between thefloor64 and thebun50 and helps to advance thebun50 in the direction ofarrow66 with movement of theconveyor60. Theslot62 may extend all the way to anopen end68 of thecassette32. This way, theconveyor60 can extend the length of thecassette32 and/or beyond the length of thecassette32 to movebuns50 from thecassette32 out of thecompartment30 to thedispenser14.

It will be recognized that the embodiment depicted inFIG.3A is schematic in nature and may used with more or fewer components as shown therein. Further examples of cassettes are provided herein and it is recognized that features between those as shown in all of the figures herein may be used in embodiments while remaining within the scope of the present disclosure.

FIG.3B depicts an example of a portion of acompartment30 of a holdingcabinet12 with acassette32 and aplurality conveyors60. Thecassette32 is exemplarily configured to receive three rows of buns, and is similar in shape and construction to those cassettes as depicted and described in further detail with respect toFIGS.4A-5C.FIG.3C is a side view taken along line C-C ofFIG.3B. Thecassette32 rests uponshelves98 which extend into the interior of thecabinet30. When positioned on theshelves98, thecassette32 is held over therespective conveyors60, which are arranged to correspond to the slots in the bottoms of the cassettes32 (seeFIGS.3A and5A-C).FIG.3B includes a second set ofshelves98 andconveyors60, but without acassette32 loaded thereon. It can be seen from this second set ofshelves98 andconveyors60 that theconveyors60 extend above a plane formed by theshelves98.

As seen inFIG.3C, when thecassette32 is loaded into the cabinet and rests upon theshelves98, theconveyors60 extend through the slots into the cassette to engage thebuns50 stored therein. Theconveyor60 extends out of a back end of thecassette32. Advancement of theconveyor60 moves abun50 out of thecassette32 to be to be delivered from thecompartment30 to thedispenser14.

Currently, baked goods often are received from a bakery in bagged “pillow packs.” The pillow packs are constructed and treated such as to create an environment suitable for holding and preserving quality of the baked goods therein. However, upon opening the pillow pack, the baked goods will quickly begin to degrade and become stale. Thus, in use, the pillow packs may be opened and the baked goods directly loaded into acassette32 and moved to the controlled environment of the holdingcabinet12. This limits the exposure of the baked goods to the ambient air and enables the holdingcabinet12 to promote baked good holding and quality. In exemplary embodiments,individual cassettes32 may be sized and/or dimensioned such as to receive the entirety of a “pillow pack” of baked goods such that thecassette32 can accommodate all of the baked goods of the “pillow pack,” once it is opened. This limits the likelihood that baked goods will be held outside of the controlled environments of the “pillow pack”, thecassette32, the holdingcabinet12. In other embodiments,cassettes32 or portions ofcassettes32 may be configured to accommodate a regular portion of a pillow pack of baked goods, for example half of a pillow pack. In this manner, twocassettes32 can be filled with the contents of an opened pillow pack.

Thecassette32 as described herein may also be used for the thawing and handling of buns removed from the pillow packs but prior to cassettes being received within the holdingcabinet12. As previously noted, to maintain the quality of buns during transport from a bakery to the restaurant, the buns may be frozen. In other settings, the buns may be shipped in uninsulated environments which may expose them to freezing temperatures. In either event, the buns may have to be thawed when they are received at the restaurant. In the embodiments, it may be advantageous for the buns to thaw outside of the enclosed environment of the pillow pack; however, it is still desirable to limit the exposure of the buns to the open air. As described herein, embodiments of thecassettes32 may be used in the thawing process to limit the amount of air surrounding the buns which will extend their shelf life when compared to leaving buns in the open air. In the embodiments described herein, eachcassette32 may be configured to nest with acassette32 positioned above or below it during a bun transfer out of the pillow pack operation in order to minimize the air circulation around the buns. Thecassette32 can be placed into athaw rack70 as will be described in further detail herein which operates to close thecassette32, minimizing air exposure. Thethaw rack70 may be held in the ambient environment of the kitchen, or may be placed in a refrigerating or a warming device to further control the temperature and environment within which the bun within thecassettes32 may thaw and be held prior to being placed in the holdingcabinet12.

Like reference numerals are used herein to denote similar components between examples while focusing the disclosure on features shown in each example. A person of ordinary skill in the art will recognize from the present disclosure that components between the various examples may be combined and recombined with more or fewer components to arrive at still further examples within the scope of the present disclosure.

FIGS.4A and4B depict an example of athawing rack70. Thethawing rack70 inFIG.4A depicts thethawing rack70 in an empty condition whileFIG.4B depicts the thawing rack filled with a plurality ofcassettes32. Thecassettes32 are exemplarily in the configuration as shown and described with respect toFIGS.5A-5C. As noted above, it is desirable to provide the buns with an environment for holding and/or thawing after the buns have been removed from the pillow packs, but prior to the buns being placed in thebun dispenser12 described above. Thethawing rack70 facilitates this holding process which may be done in an ambient environment of the kitchen or may be done in a cooler, warmer, or other controlled environment.

Referring toFIG.4A, thethawing rack70 includes a plurality ofshelves72. In embodiments, theshelves72 are vertically spaced apart at an exemplary dimension configured to receive twocassettes32 in the vertical dimension betweenadjacent shelves72. However, it will be recognized that in other embodiments a greater or a lesser space betweenadjacent shelves72 may be provided. Theshelves72 are secured to a frame74 that exemplarily include vertical components and horizontal components which may be secured by a rivet or a welding or another form of fastening as will be recognized by a person of ordinary skill in the art. The frame74 may further includewheels76 which enable thethawing rack70 to be moved within a kitchen and for example into a controlled environment area or to be moved into a position adjacent to thebun holding cabinet12 for loading of thebun holding cabinet12 withcassettes32 filled with buns.

Theshelves72 are further dimensioned such as to receive twocassettes32 horizontally adjacent to one another across the width of ashelf72. However, it will be recognized that dimensioning of thecassettes32 and/or theshelves72 may be made such as to accommodate more or fewer than twocassettes32 across a width of ashelf72. The widths of theshelf72 may further be defined bylips78 extending from theshelves72 and secured to the frame74. Theshelves72 further include backwalls80 that extend across the width of theshelves72 at the rear of theshelves72 and are secured to the frame74.

As depicted inFIG.4B, a plurality ofcassettes32, filled with buns, are loaded into thethawing rack70 to hold the buns within thecassettes32 until the buns can be loaded into the bun holding cabinet. In exemplary embodiments, thecassettes32 may be color coded or include some further type of identification such as to identify the type of bun contained withindifferent cassettes32. In an example, different colors ofcassettes32 may be used to distinguish between regular buns or club buns while still other colors may identify wheat buns, brioche buns, ciabatta buns, hoagie rolls, or other types of baked goods as may be used within the systems of the present disclosure.

As discussed above and will be discussed in further detail, thecassettes32 are exemplarily partially open withslots62 in thefloors64 andopen end68 to the rear of thecassette32. In the embodiment of thethawing rack70, theshelf72 and theend plate80 are configured and dimensioned such as to engage with thecassette32 to close off these openings of thecassette32 in a manner such as to provide the limitation of circulation of the air surrounding the buns held within thecassettes32 with air external to thecassettes32 as well as to limit the circulation of the air within thecassettes32. By blocking theslot62 and theopen end68 of thecassettes32 respectively with theshelf72 and theback wall80, an environment about the buns within thecassettes32 is provided with a limited exposure to the ambient air.

FIG.4B further depicts two configurations or manners in which theslots62 may be blocked or partially blocked to limit exposure to ambient air. Theslots62 may be blocked by thecassette32 resting on a shelf which extends across theslot62. Thecovers82 of thecassettes32 may includeridges96, which are described in further detail with respect toFIGS.5A-5C. Thecassettes32 may further be stacked on top of each other, with theridges96 of alower cassette32 nesting within theslot62 of theupper cassette32.

FIGS.5A-5C provide a more detailed depiction of an exemplary embodiment ofcassette32.FIG.5A is a top rear perspective view of thecassette32.FIG.5B is a top front perspective view of thecassette32 with thecover82 in an open or partially open configuration.FIG.5C is a bottom rear perspective view of thecassette32 in a closed configuration. As previously described, thecassette32 is configured to hold a plurality ofbuns50 therein. While thecassette32 depicted inFIGS.5A-5C exemplarily provides thebuns50 in threelanes84, it will be recognized that other embodiments ofcassettes32 may have more or fewer than threelanes84. Thelanes84 are exemplarily defined in acassette body86 with aside wall88, afront wall90, andintermediate walls92. Thecassette32 is open towards the rear face of thecassette32 opposite thefront wall90. Thecover82 is hingedly connected to thebody86, for example, at apivot point94. Thecover82 rotates about thepivot point94 between a closed position as shown inFIGS.5A and5C and an open position exemplarily as shown inFIG.5B. The opening ofcover82 facilitates the filling of thecassette32 withbuns50 from a pillow pack.

As best shown inFIG.5A, thecover82 further includesridges96. Theridges96 are exemplarily dimensioned and otherwise configured to be received within theslot62 of an adjacently abovecassette32. Theridges96 thereby close theslot62 of the adjacently abovecassette32 when stacked thereon as for example shown inFIG.4B. This facilitates closure of the environment about thebuns50 within the cassette limiting and/or minimizing air exchange and circulation therein. Theridges96 may exemplarily include ribbon or textural features or a material, for example, an elastomeric material to further facilitate the engagement and closure of theridges96 within theslots62.

As described above, exemplary processes for handling baked goods include a number of actions performed by and with components of the bakedgoods handling system10, including, but not limited to thebun holding cabinet12. These actions may be performed by individual initiation at each of the components, for example, upon user inputs or actuations at each of the components as described herein, or may be performed automatedly based upon instructions provided by the KMS through the IOT system as described above. In still further embodiments, the components of the baked goods handling system may communicate directly with one another for example by wired or wireless communication. In a still further embodiment, the bakedgoods handling system10 may be integrated into a single apparatus that provides holding, dispensing and toasting functions.

Citations to a number of references are made herein. The cited references are incorporated by reference herein in their entireties. In the event that there is an inconsistency between a definition of a term in the specification as compared to a definition of the term in a cited reference, the term should be interpreted based on the definition in the specification.

In the above description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different systems and method steps described herein may be used alone or in combination with other systems and methods. It is to be expected that various equivalents, alternatives and modifications are possible within the scope of the appended claims.

The functional block diagrams, operational sequences, and flow diagrams provided in the Figures are representative of exemplary architectures, environments, and methodologies for performing novel aspects of the disclosure. While, for purposes of simplicity of explanation, the methodologies included herein may be in the form of a functional diagram, operational sequence, or flow diagram, and may be described as a series of acts, it is to be understood and appreciated that the methodologies are not limited by the order of acts, as some acts may, in accordance therewith, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology can alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all acts illustrated in a methodology may be required for a novel implementation.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims (20)

We claim:

1. A bun handling system, comprising:

a cassette comprising opposed side walls, a front wall, an open rear face opposite the front wall, and a floor between the opposed side walls;

wherein a cover extends between the opposed side walls above the floor, wherein the cover is movable relative to the opposed side walls and the floor; and

wherein a slot is defined through the floor from the open rear face in a direction towards the front wall.

2. The bun handling system ofclaim 1, wherein the floor of the cassette further extends interior from the front wall, separating the slot from the front wall.

3. The bun handling system ofclaim 2, further comprising a plurality of lanes defined within the cassette between the opposed side walls, each of the lanes of the plurality separated from an adjacent lane of the plurality by an intermediate wall.

4. The bun handling system ofclaim 3, wherein the cassette comprises a plurality of slots, the plurality of slots including the slot, and each slot of the plurality of slots extends through the floor from the open rear face in a direction towards the front wall, each lane of the plurality of lanes having a slot of the plurality of slots.

5. The bun handling system ofclaim 4, wherein the cover further comprises a plurality of ridges extending outwards from the cover, and each ridge of the plurality of ridges is vertically aligned with a slot of the plurality of slots.

6. The bun handling system ofclaim 5, wherein the cassette is a first cassette and further comprising a second cassette, wherein a plurality of ridges extending from a cover of the second cassette are dimensioned to nest within corresponding slots of the plurality of slots of the first cassette when the first cassette is stacked upon the second cassette.

7. The bun handling system ofclaim 1, further comprising a bun holding cabinet defining a compartment, the compartment of the bun holding cabinet configured to removably receive the cassette.

8. The bun handling system ofclaim 7, wherein the bun handling system is configured to dispense a bun from a dispense point of the bun handling system to a toaster adjacent to the compartment.

9. The bun handling system ofclaim 8, wherein the cassette is movable within the compartment to orient the cassette relative to the dispense point.

10. The bun handling system ofclaim 9, further comprising a first door into the compartment and configured to receive the cassette filled with a plurality of buns therethrough and comprising a second door into the compartment and configured for removal of the cassette after the buns are dispensed.

11. The bun handling system ofclaim 7, further comprising a conveyor arranged within the compartment, the conveyor receivable within the slot to extend through the slot to engage a bun within the cassette.

12. The bun handling system ofclaim 7, further comprising:

wherein the cassette comprises a plurality of lanes separated from an adjacent lane of the plurality of lanes by an intermediate wall, and a plurality of slots including the slot, each slot of the plurality of slots extends through the floor from the open rear face in a direction towards the front wall, each lane of the plurality of lanes having a slot of the plurality of slots;

a plurality of conveyors arranged within the compartment, each of the conveyors of the plurality of conveyors configured to be receivable within a slot of the plurality of slots;

wherein the plurality of conveyors extend through the plurality of slots to engage buns in each lane of the cassette.

13. The bun handling system ofclaim 12, wherein when the plurality of conveyors are received within the plurality of slots, the plurality of conveyors extend out of the open rear face of the cassette and are operable to move buns from each lane of the cassette out of the open rear face of the cassette.

14. The bun handling system ofclaim 12, wherein the compartment further comprises at least one shelf extending interior the compartment, wherein when the cassette rests on the at least one shelf, the plurality of conveyors are positioned within the plurality of slots.

15. The bun handling system ofclaim 7, further comprising a thawing rack with a plurality of shelves, each shelf of the thawing rack configured to receive the cassette, the thawing rack further comprising a plurality of back walls each oriented relative to one of the shelves of the plurality of shelves;

wherein when the cassette is received on a shelf of the plurality of shelves, the shelf covers the slot and the back wall covers the open rear face.

16. The bun handling system ofclaim 15, wherein the shelves of the plurality of shelves are spaced apart at a distance to accommodate at least two cassettes in a vertical stack.

17. The bun handling system ofclaim 16, wherein the cassette is a first cassette and further comprising a second cassette, wherein a plurality of ridges extending from a cover of the second cassette are dimensioned to nest within corresponding slots of the plurality of slots of the first cassette when the first cassette is stacked upon the second cassette.

18. A bun handling system, comprising:

a plurality of cassettes, each cassette of the plurality comprising: opposed side walls, a front wall, an open rear face opposite the front wall, and a floor between the opposed side walls;

wherein a plurality of lanes are defined within the cassette between the opposed side walls, each of the lanes separated from an adjacent lane of the plurality of lanes by an intermediate wall, and a plurality of slots extend through the floor from the open rear face of the cassette in a direction towards the front wall and each lane of the plurality of lanes includes a slot of the plurality of slots; and

a cover extends between the opposed side walls above the floor, wherein the cover is movable relative to the opposed side walls and the floor, the cover comprising a plurality of ridges extending outward from the cover and each ridge of the plurality of ridges is vertically aligned with a slot of the plurality of slots; and

a bun holding cabinet defining a compartment, the compartment of the bun holding cabinet configured to removably receive each cassette of the plurality of cassettes, the bun holding cabinet comprising:

a plurality of conveyors arranged within the compartment, each of the conveyors of the plurality of conveyors configured to be receivable within a slot of the plurality of slots;

wherein the plurality of conveyors extend through the plurality of slots to engage buns in each lane of the cassette, wherein the plurality of conveyors extend out of the open rear face of the cassette and are operable to move buns from each lane of the cassette out of the open rear face of the cassette.

19. The bun handling system ofclaim 18, further comprising a thawing rack with a plurality of shelves, each shelf of the thawing rack configured to receive at least one cassette of the plurality of cassettes, the thawing rack further comprising a plurality of back walls each oriented relative to one of the shelves of the plurality of shelves;

wherein when the cassette is received on a shelf of the plurality of shelves, the shelf covers the slot and the back wall covers the open rear face.

20. A method of dispensing buns from the bun handling system ofclaim 18, the method comprising:

receiving a plurality of buns in each lane of each of the plurality of cassettes;

receiving the plurality of cassettes within the compartment of the bun holding cabinet;

positioning the plurality of conveyors through the slots of a cassette of the plurality of cassettes to engage the plurality of buns within the cassette with the conveyors; and

advancing at least one conveyor of the plurality of conveyors to move a bun out of the cassette to a dispense point of the bun holding cabinet.

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